Manufacturing method for carded woolen yarn

ABSTRACT

Top making apparatus is attached to a woolen card.  
     Materials usually to be processed on a woolen card are fed and the delivered web is guided by the top making apparatus and ball tops are formed by the top making apparatus.  
     This top is processed on cotton spinning system. Finder and evener yam can spun with the top.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to the field of carded woolen yam and in particular, manufacturing method for carded woolen yarn.

[0003] 2. DESCRIPTION OF THE BACKGROUND

[0004] Woolen yarns are spun on woolen spinning system which is composed of woolen card and mule spinning machine. Dyed fibers are fed to a woolen card and bundle of slivers is produced by splitting card web. Woolen yarn is spun on mule spinning machine with these slivers. This woolen spinning system is simple and effective to spin fibers of short length which can not be spun on worsted spinning system. But only coarser count of yarn can be spun on this system. More over the yarn evenness is not good and the strength of yarn is inferior. Especially finer yarn spun on this system require stiff cost increase because of sharp drop in productivity. So, usually single yarn is applied to make sweaters, resulting in distortion of garment. Finer yarn can be produced with the same dyed short fibers by this invention. This finer yarn can be plied with comparatively low cost. Sweaters made with this doubled and twisted yarn has better appearance without distortion of fabric.

SUMMARY OF THE INVENTION

[0005] Various fibers of short length are dyed in loose fiber dyeing machine, dried, oiled and fed to conventional wool card, in front of which top making apparatus is attached to receive the web which is flowing out from the doffer of final mountain. The web is converted top of ball shape. This top is fed to the draw frame of cotton system. After four passage of drawing, the sliver are fed to the roving frame to make roving. On spinning frame, woolen yarn is spun with this rovings.

[0006] Parallel of fiber is improved by drawing. The yarn has better evenness and better strength. Much finer yarn can acquired with short fibers which are not suitable for worsted spinning.

BRIEF DESCRIPTION OF DRAWINGS

[0007]FIG. 1 shows process of conventional woolen spinning

[0008]FIG. 2 shows process of spinning by the invention

[0009]FIG. 3 shows recessed area of cut boss and state of action of fiber fleece against apron. In this figure, the reference numerals are bottom roller1, non-cut area of top roller boss2, cut area of top roller boss3, straight apron4, bent apron by fiber fleece which is being passed between bottom and top apron.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0010] The primary objective is to spin finer yarn, that is, {fraction (1/30)} or finer count with short fibers like lamb's wool, cashmere, carbonized pieces wool, etc, whose usual yarn count is coarser than {fraction (1/15)}. These fiber are not suitable to process on worsted spinning system because of the shortness of the fiber length, and of course, not suitable to process on cotton spinning system because these are too long and it is too difficult to open the fibers. The woolen card is effective and convenient to process the dyed and blended fibers. The sliver splitted and delivered to make bundle is processed on mule spinning frame. So this system is only two process to make yarn from fed materials. It is very simple and cost effective.

[0011] But the yarns are too coarse, weak and uneven.

[0012] Generally worsted yarns are doubled and twisted to make sweaters to have good appearance and to prevent distortion. But woolen yarns are too coarse to make doubled yarn. And woolen yarns are much weak for weaving. To make finer yarn on woolen system, the size of sliver from the woolen card must be reduced according to the yarn count. So if yarn number is finer by one-half, the production rate of sliver from the card is reduced by one-half As the sliver size is thinner and weaker, the speed of doffer must be slower. So the combined effect of these two factors reduces the production rate much more than reduction rate of the yarn size. The decrease of production rate of mule spinning is the same as that of woolen card by reduction of yarn size. Those reductions of production rate make the yarn cost rise sharply. Additionally, the finer wool must be selected to spin finer yarn and this adds the cost heavily to the already expensive production cost.

[0013] In this invention, the delivered web is taken from the doffer of the last mountain to make ball top by means of top making apparatus. The top making apparatus is attached to the woolen card which is the same apparatus as attached to worsted card. The top is fed on the draw frame of the cotton spinning system. The fiber length of the top is much longer than that of cotton. The distance between rollers according to the fiber length is controlled with the technique described in U.S. Pat. No. 5,638,580. Too long fibers may be broken by means of adjusting the distance of rollers of drawing frames. To control fibers which are much longer than cotton on the draw frame of the cotton system is important. Usually, four passage of drawing is applied to get smooth distribution of fiber length. The slivers produced from the drawing process are fed on roving frame. If the longest fiber length is less than 55 mm, the weighting and top roller arrangement is regularly set. But if the longest fiber is longer than 55 mm, middle top rollers are changed to the grooved roller shown as FIG. 3. The roving produced from the roving frame is processed on the ring frame to make yam. If the longest fiber length is longer than 55 mm, the grooved middle top rollers are applied. Drafting ratio is much less comparing conventional cotton spinning. Twist per meter is higher than regular woolen yarn by 10˜15%.

[0014] This extra twist is untwisted by doubling and twisting.

[0015] Cotton system is inconvenient to process dyed fibers like cotton, rayon and nylon lending with wool because changing of small lot size is almost impossible on blowing and carding machine of cotton system. By this invention, the convenient and effective woolen card is utilized to process almost any fiber to get good quality of woolen yarn. Concerning the transferring of material from woolen card to the drawing frame, other methods can be applied, for example, the delivering web from the doffer of woolen card can be condensed and coiled to a can.

EXAMPLE 1

[0016] Carbonized lamb's wool(18μ)30%, carbonized pieces wool(18μ)30%. Wool top(18μ)40% was mixed, dyed and oiled by conventional method. The dyed fiber was fed to the four mountain woolen card equipped with top making apparatus, making ball top.

[0017] The top was processed on draw frame of cotton system. The distance between first and 3rd roller was adjusted as 110 mm at the passage of the drawing, and the gauge was adjusted, third and last passage. On roving frame, the distance between front and second roller was set as 60 mm and the grooved top rollers were applied. The grooved top rollers were applied on spinning frame to spin {fraction (1/30)}. The twist per meter was 540, and R.P.M of spindle was 8,000. The spun yam was doubled and twisted by 200 T.P.M. Sweaters were made with 12 gauge flat knitting machine. The sweaters were with good appearance, and good handle without distortion.

EXAMPLE 2

[0018] 10% of cashmere, 40% of carbonized wool (20μ), 30% of rayon(2d×51 mm) and 20% of nylon(2d×51 mm) was mixed, dyed and oiled.

[0019] The fibers were fed to the woolen card equipped with top making apparatus to make ball top. The top was processed on the drawing frame with roller gauge of 64 mm. The second passage of drawing was processed with roller gauge of 55 mm. The third and last passage was processed with the same 55 mm gauge. On the roving frame, regular roller setting was applied roller gauge of 55 mm. Regular roller setting was applied with on the ring spinning frame with roller gauge 55 mm, spindle speed 9,000 R.P.M, yarn count {fraction (1/36)}, and 590 T.P.M. And T.P.M of doubling and twisting was 230. Sweater was knitted by 16 gauge of flat knitting machine. The sweater was with good quality, finer texture and handle of cashmere. 

What is claimed is;
 1. A manufacturing method for carded woolen yarn on combined system of woolen card and cotton system, preparing dyed or raw materials by means of conventional woolen system, feeding to the woolen card, condensing web from the doffer of the woolen card doffer, forming top or coiled sliver in a can to transfer to the drawing frame of the cotton system, drawing the sliver on the drawing frame adjusting roller gauge according to fiber length through suitable passage, forming roving on roving frame with the drawn sliver adjusting roller frame with the fiber length and if required, using grooved roller, spinning yarn with the roving adjusting roller gauge according to the fiber length and if required, using the grooved roller. 